Evaluation of adiabatic runaway reaction of methyl ethyl ketone peroxide by DSC and VSP2

Methyl ethyl ketone peroxide (MEKPO) is generally applied to manufacturing in the polymerization processes. Due to thermal instability and high exothermic behaviors of MEKPO, if any operation is undertaken recklessly or some environmental effect is produced suddenly during the processes, fires and explosions may inevitably occur. In this study, thermal analysis was evaluated for MEKPO by differential scanning calorimetry (DSC) test. Vent sizing package 2 (VSP2) was used to analyze the thermal hazard of MEKPO under various stirring rates in a batch reactor. Thermokinetic and safety parameters, including exothermic onset temperature (T ₀), maximum temperature (T _max), maximum pressure (P _max), self-heating rate (dT dt ⁻¹), pressure rise rate (dP dt ⁻¹), and so on, were discovered to identify the safe handling situation. The stirring rates of reactor were confirmed to affect runaway and thermal hazard characteristics in the batch reactor. If the stirring rate was out of control, it could soon cause a thermal hazard in the reactor.     

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Organic peroxides (OPs) have caused many momentous explosions and runaway reactions, resulting from thermal instability, chemical pollutants, and even mechanical shock. In Taiwan, dicumyl peroxide (DCPO), due to its unstable reactive nature, has caused two thermal explosions and runaway reaction incidents in the manufacturing process. To evaluate thermal hazards of DCPO in a batch reactor, we studied thermokinetic parameters, such as heat of decomposition (†H _d), exothermic onset temperature (T ₀), maximum temperature rise ((dT/dt)_max), maximum pressure rise ((dP/dt)_max), self-heating rate (dT/dt), etc., via differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2).     

Thermal runaway analyses for two organic peroxides with H2O and dry fire-extinguishing chemicals by DSC and VSP2

In recent years, organic peroxides, including methyl ethyl ketone peroxide (MEKPO) and cumene hydroperoxide (CHP), have often caused thermal runaway reactions, fires, and thermal explosions worldwide. Under normal circumstances, H₂O and dry fire-extinguishing chemicals are often employed to eliminate fire situations. We evaluated the thermal runaway reaction for MEKPO and CHP mixed with H₂O and dry fire-extinguishing chemicals by differential scanning calorimetry, and thermal runaway reaction for CHP mixed with dry fire-extinguishing chemicals by vent sizing package 2. The results showed that ABC dry chemical, BC dry chemical, and XBC dry chemical all caused the decomposition of MEKPO to occur at lower onset temperature and H₂O caused the ΔH _d of MEKPO to become higher. On the other hand, H₂O and XBC dry chemical induced the decomposition of CHP to occur at lower onset temperature as well as lower thermal explosion temperature. The maximum of self-heating rate ((dT/dt)_max) and the maximum pressure-rise rate ((dP/dt)_max) of CHP mixed with dry fire-extinguishing chemicals were measured lower than CHP alone. The results indicated that MEKPO and CHP are highly hazardous when mixed with H₂O and some dry fire-extinguishing chemicals. In view of loss prevention, the results can be useful references for fire fighters dealing with thermal upsets in chemical plants.     

Effects of cumene hydroperoxide on phenol and acetone manufacturing by DSC and VSP2

Cumene hydroperoxide (CHP) being catalyzed by acid is one of the crucial processes for producing phenol and acetone globally. However, it is thermally unstable to the runaway reaction readily. In this study, various concentrations of phenol and acetone were added into CHP for determination of thermal hazards. Differential scanning calorimetry (DSC) tests were used to obtain the parameters of exothermic behaviors under dynamic screening. The parameters included exothermic onset temperature (T ₀), heat of decomposition (ΔH _d), and exothermic peak temperature (T _p). Vent sizing package 2 (VSP2) was employed to receive the maximum pressure (P _max), the maximum temperature (T _max), the self-heating rate (dT/dt), maximum pressure rise rate ((dP/dt)_max), and adiabatic time to maximum rate ((TMR)_ad) under the worst case. Finally, a procedure for predicting thermal hazard data was developed. The results revealed that phenol and acetone sharply caused a exothermic reaction of CHP. As a result, phenol and acetone are important indicators that may cause a thermal hazard in the manufacturing process.     

Thermal decomposition of hydrogen peroxide in the presence of sulfuric acid

Hydrogen peroxide (H₂O₂) is popularly employed as a reaction reagent in cleaning processes for the chemical industry and semiconductor plants. By using differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2), this study focused on the thermal decomposition reaction of H₂O₂ mixed with sulfuric acid (H₂SO₄) with low (0.1, 0.5 and 1.0 N), and high concentrations of 96 mass%, respectively. Thermokinetic data, such as exothermic onset temperature (T ₀), heat of decomposition (ΔH _d), pressure rise rate (dP/dt), and self-heating rate (dT/dt), were obtained and assessed by the DSC and VSP2 experiments. From the thermal decomposition reaction on various concentrations of H₂SO₄, the experimental data of T ₀, ΔH, dP/dt, and dT/dt were obtained. Comparisons of the reactivity for H₂O₂ and H₂O₂ mixed with H₂SO₄ (lower and higher concentrations) were evaluated to corroborate the decomposition reaction in these systems.     

Runaway effects of nitric acid on methyl ethyl ketone peroxide by TAM III tests

Methyl ethyl ketone peroxide (MEKPO) is an unstable material above certain limits of temperature, decomposing into chain reactions by radicals. The influence of runaway reactions on this basic characteristic was assessed by evaluating kinetic parameters, such as activation energy (E _a ), frequency factor (A), etc., by thermal activity monitor III (TAM III). This was done under three isothermal conditions of 70, 80, and 90 °C, with MEKPO 31 mass% combined with nitric acid (HNO₃ 6 N) and sodium nitrate (NaNO₃ 6 N). Nitric acid mixed with MEKPO gave the maximum heat of reaction (△H _d ) and also induced serious reactions in the initial stage of exothermic process under the three isothermal temperatures. The time to maximum rate (TMR) also decreased when HNO₃ was mixed with MEKPO. Thus, MEKPO combined with HNO₃ 6 N forms a very hazardous mixture. Results of this study will be provided to relevant plants for alerting their staff on adopting best practices in emergency response or accident control.     

Explosion evaluation and safety storage analyses of cumene hydroperoxide using various calorimeters

Plenty of thermal explosions and runaway reactions of cumene hydroperoxide (CHP) were described from 1981 to 2010 in Taiwan. Therefore, a thermal explosion accident of CHP in oxidation tower in 2010 in Taiwan was investigated because of piping breakage. In general, high concentration of CHP for thermal analysis using the calorimeter is dangerous. Therefore, a simulation method and a kinetic parameter were used to simulate thermal hazard of high concentrations of CHP only by the researcher. This study was applied to evaluate thermal hazard and to analyze storage parameters of 80 and 88 mass% CHP using three calorimeters for the oxidation tower, transportation, and 50-gallon drum. Differential scanning calorimetry (DSC) (a non-isothermal calorimeter), thermal activity monitor III (TAM III) (an isothermal calorimeter), and vent sizing package 2 (VSP2) (an adiabatic calorimeter) were employed to detect the exothermic behavior and runaway reaction model of 80 and 88 mass% CHP. Exothermic onset temperature (T ₀), heat of decomposition (ΔH _d), maximum temperature (T _max), time to maximum rate under isothermal condition (TMR_iso) (as an emergency response time), maximum pressure (P _max), maximum of self-heating rate ((dT/dt)_max), maximum of pressure rise rate ((dP/dt)_max), half-life time (t _1/2), reaction order (n), activation energy (E _a), frequency factor (A), etc., of 80 and 88 mass% CHP were applied to prevent thermal explosion and runaway reaction accident and to calculate the critical temperature (T _c). Experimental results displayed that the n of 80 and 88 mass% CHP was determined to be 0.5 and the E _a of 80 and 88 mass% CHP were evaluated to be 132 and 134 kJ mol^?1, respectively.     

Thermal hazard evaluation of tert-butyl peroxide using non-isothermal and adiabatic calorimetric approaches

Tert-butyl peroxide (TBPO), is a typical organic peroxides (OPs),which is widely applied as initiator in poly-glycidyl methacrylate (PGMA) reaction, and is employed to provide a free-radical in frontal polymerization, and which has also caused many thermal runaway reactions and explosions worldwide. To find an unknown and insufficient hazard information for an energetic material, differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2) were employed to detect the fundamental thermokinetic parameters involving the exothermic onset temperature (T ₀), heat of decomposition (??H _d), temperature rise rate (dT · dt ^?1), time to maximum rate under adiabatic situation (TMR_ad), pressure rise rate (dP · dt ^?1), and maximum pressure (P _max), etc. The T ₀ was calculated to be 130?°C using DSC and VSP2. Activation energy (E _a) of TBPO was evaluated to be 136?kJ?mol^?1 by VSP2. In view of the loss prevention, calorimetric applications and model evaluation to integrate thermal hazard development are adequate means for inherently safer design.     

Evaluation of thermal hazard for lauroyl peroxide by VSP2 and TAM III

When above certain temperature limits, lauroyl peroxide is an unstable material. If the thermal source cannot be properly governed during any stage in the preparation, manufacturing process, storage or transport, runaway reactions may inevitably be induced immediately. In this study, the influence of runaway reactions on its basic thermal characteristic was assessed by evaluating thermokinetic parameters, such as activation energy (E _a) and frequency factor (A) by thermal activity monitor III (TAM III). This was achieved under five isothermal conditions of 50, 60, 70, 80, and 90?°C. Vent sizing package 2 (VSP2) was employed to determine the maximum pressure (P _max), maximum temperature (T _max ), maximum self-heating rate ((dT?dt ^?1)_max), maximum pressure rise rate ((dP?dt ^?1)_max), and isothermal time to maximum rate ((TMR)_iso) under the worst case. Results of this study will be provided to relevant plants for adopting best practices in emergency response or accident control.     

Self-reactive rating of thermal runaway hazards on 18650 lithium-ion batteries

Vent sizing package 2 (VSP2) was used to measure the thermal hazard and runaway characteristics of 18650 lithium-ion batteries, which were manufactured by Sanyo Electric Co., Ltd. Runaway reaction behaviors of these batteries were obtained: 50% state of charge (SOC), and 100% SOC. The tests evaluated the thermal hazard characteristics, such as initial exothermic temperature (T ₀), self-heating rate (dT?dt ^?1), pressure-rise rate (dP?dt ^?1), pressure temperature profiles, maximum temperature, and pressure which were observed by adiabatic calorimetric methodology via VSP2 using customized test cells. The safety assessment of lithium-ion cells proved to be an important subject. The maximum self-heating rate (dT?dt ^?1)_max and the largest pressure-rise rate (dP?dt ^?1)_max of Sanyo 18650 lithium-ion battery of 100% SOC were measured to be 37,468.8???C?min^?1 and 10,845.6?psi?min^?1, respectively, and the maximum temperature was 733.1???C. Therefore, a runaway reaction is extremely serious when a lithium-ion battery is exothermic at 100% SOC. This result also demonstrated that the thermal VSP2 is an alternative method of thermal hazard assessment for battery safety research. Finally, self-reactive ratings on thermal hazards of 18650 lithium-ion batteries were studied and elucidated to a deeper extent.     

Thermal explosion simulation and incompatible reaction of dicumyl peroxide by calorimetric technique

Dicumyl peroxide (DCPO) is usually employed as an initiator for polymerization, a source of free radicals, a hardener, and a linking agent. In Asia, due to its unstable reactive nature, DCPO has caused many thermal explosions and runaway reaction incidents in the manufacturing process. This study was conducted to elucidate its essentially thermal hazard characteristics. In order to analyze the runaway behavior of DCPO in a batch reactor, thermokinetic parameters, such as heat of decomposition (ΔH _d) and exothermic onset temperature (T ₀), were measured via differential scanning calorimetry (DSC). Thermal runaway phenomena were then thoroughly investigated by DSC. The thermokinetics of DCPO mixed with acids or bases were determined by DSC, and the experimental data were compared with kinetics-based curve fitting of thermal safety software (TSS). Solid thermal explosion (STE) and liquid thermal explosion (LTE) simulations of TSS were applied to determine the fundamental thermal explosion behavior in large tanks or drums. Results from curve fitting indicated that all of the acids or bases could induce exothermic reactions at even an earlier stage of the experiments. In order to diminish the extent of hazard, hazard information must be provided to the manufacturing process. Thermal hazard of DCPO mixed with nitric acid (HNO₃) was more dangerous than with other acids including sulfuric acid (H₂SO₄), phosphoric acid (H₃PO₄), and hydrochloric acid (HCl). By DSC, T ₀, heat of decomposition (ΔH _d), and activation energy (E _a) of DCPO mixed with HNO₃ were calculated to be 70 °C, 911 J g⁻¹, and 33 kJ mol⁻¹, respectively.     

Reaction hazard analysis for cumene hydroperoxide with sodium hydroxide or sulfuric acid

Organic peroxides (OPs) are very susceptible to thermal sources, chemical pollutants or even mechanical shock. Over the years, they have caused many serious explosions. Cumene hydroperoxide (CHP) is widely employed to produce phenol and dicumyl peroxide (DCPO) in the manufacturing process. Differential scanning calorimetry (DSC) and thermal activity monitor (TAM) were employed to determine the potential thermal hazards and thermokinetic parameters (such as exothermic onset temperature (T ₀), maximum temperature (T _max), and enthalpy (ΔH)) of CHP mixed with sodium hydroxide (NaOH) and sulfuric acid (H₂SO₄). High performance liquid chromatography (HPLC) was used to analyze the concentration vs. time of CHP.When CHP is mixed with NaOH, the T ₀ is induced earlier and reactions become more intricate than the pure CHP solution. CHP added to NaOH or H₂SO₄ is more dangerous than pure CHP alone. Depending on the operating conditions, NaOH and H₂SO₄ are the incompatible chemicals for CHP.     

Flammability properties analysis of methylphenol-carbonate in diphenylcarbonate production process

Diphenylcarbonate (DPC) has been regarded as a potential substitute material for highly toxic phosgene, reacting with bisphenol A (BPA) in a phosgene-free process to produce polycarbonate (PC). For synthesizing DPC, methylphenylcarbonate (MPC) was the critical intermediate with potential flammability in a transesterification reaction from dimethylcarbonate (DMC) and phenol. Under the National Fire Protection Association (NFPA) criterion, MPC is viewed as one sort of combustible liquid (Class IIIB). Once it fires or burns during storage, operation or transportation, it can cause a serious fire and explosion. However, researches are still scanty in mentioning the basic but crucial fire and explosion features of MPC to date. A sound background of material safety properties is essential for safe handling; in particular, flammability information is extremely crucial for a specific chemical during a unit operation to prevent any fire and explosion hazards. In this study, we investigated the explosion limits (LEL, UEL), maximum explosion pressure (P _max), maximum rate of explosion pressure rise ((dP/dt)_max), and gas or vapor explosion constant (K _g) of MPC, according to its practical operating conditions (1 atm, 250°C, 21 vol.% O₂) and by means of a 20 L vessel (20-L-Apparatus). By surveying and defining the experimental data through flammability tests, these basic but crucial safety-related parameters on flammability characteristics of MPC were proposed, so as to advance understanding and to avoid fire and explosion accidents for such relevant processes.     

Effects of flammability characteristics of steam inerting to solution of acetone in water

Preventing accidental explosions of flammable liquid/gas mixtures is very important. As far as flammability characteristics are concerned, we simulated the effects of inert liquid/gas, which was filled with reactors, vessels, or closed space, employed in the chemical process industries. The inert liquid/gas (H₂O) weakened the oxygen concentration and reduced solvent vapor concentration in a 20-L-Apparatus. This study investigated the flammability characteristics of acetone/water solutions (100/0, 75/25, 50/50, and 25/75 vol.%) that are controlled at a temperature of 150°C and pressures of 101/202 kPa, respectively. The flammability parameters included flammability limits (LEL and UEL), maximum explosion pressure (P _max), maximum explosion pressure rise ((dP dt ⁻¹)_max), and vapor deflagration index (K _g). The results of a series of experimental tests showed that UEL, P _max, and K _g all decreased with steam rising under the experimental conditions. The results can be applied to process safety design/operation for identifying whether the inert liquid/gas (H₂O) content has any substantial effects in reducing the fire and explosion hazard of the solution of interest.     

Runaway reaction of lauroyl peroxide with nitric acid by DSC

Pooling lauroyl peroxide (LPO) with nitric acid, we used differential scanning calorimetry (DSC) to assess the thermokinetic parameters, such as exothermic onset temperature (T ₀), heat of decomposition (ΔH _d), frequency factor (A), and the other safety parameters. When LPO was contaminated with nitric acid (HNO₃), we found the exploder 1-nitrododecane. Obvious products were sensitive and hazardous chemicals. Concentration reaching 1–12 N HNO₃ emitted a large amount of heat. This study combined with curve-fitting method to elucidate its unsafe characteristics and thermally sensitive structure to help prevent runaway reactions, fires and explosions in the process environment. According to the findings and the concept of inherently safer design, LPO runaway reactions could be adequately prevented in the relevant plants.     

Thermal hazard evaluations of 18650 lithium-ion batteries by an adiabatic calorimeter

In this study, the thermal hazard features of various lithium-ion batteries, such as LiCoO₂ and LiFePO₄, were assessed properly by calorimetric techniques. Vent sizing package 2 (VSP2), an adiabatic calorimeter, was used to measure the thermal hazards and runaway characteristics of the 18650 lithium-ion batteries under an adiabatic condition. The thermal behaviors of the lithium-ion batteries were obtained at normal and abnormal conditions in this study. The critical parameters for thermal hazardous behavior of lithium-ion batteries were obtained including the exothermic onset temperature (T ₀), heat of decomposition (ΔH), maximum temperature (T _max), maximum pressure (P _max), self-heating rate (dT/dt), and pressure rise rate (dP/dt). Therefore, the result indicates the thermal runaway situation of the lithium-ion battery with different materials and voltages in view the of TNT-equivalent method by VSP2. The hazard gets greater with higher voltage. Without the consideration of other anti-pressure measurements, different voltages involving 3.3, 3.6, 3.7, and 4.2 V are evaluated to 0.11, 0.23, 0.88, and 1.77 g of TNT. Further estimation of thermal runaway reaction and decomposition reaction of lithium-ion battery can also be confirmed by VSP2. It shows that the battery of a fully charged state is more dangerous than that of a storage state. The technique results showed that VSP2 can be used to strictly evaluate thermal runaway reaction and thermal decomposition behaviors of lithium-ion batteries. The loss prevention and thermal hazard assessment are very important for development of electric vehicles as well as other appliances in the future. Therefore, our results could be applied to define important safety indices of lithium-ion batteries for safety concerns.     

Thermal explosion simulation of methyl ethyl ketone peroxide in three types of vessel under the same volume by explosion models

Methyl ethyl ketone peroxide (MEKPO), which has highly reactive and exothermically unstable characteristics, has been extensively employed in the chemical industries. It has also caused many thermal explosions and runaway reaction accidents in manufacturing processes during the last three decades in Taiwan, Japan, Korea, and China. The goal of this study was to simulate thermal upset by MEKPO for an emergency response. Vent sizing package 2 (VSP2) was used to determine the thermokinetics of 20 mass% MEKPO. Data of thermokinetics and hazard behaviors were employed to simulate thermal explosion in three types of vessel containing 20 mass% MEKPO under various scenarios at the same volume. To compare and appraise the difference of important parameters, such as maximum temperature (T _max), maximum pressure (P _max), etc. This was necessary and useful for investigating the emergency response procedure associated with industrial applications.     

Reaction hazard analysis for the thermal decomposition of cumene hydroperoxide in the presence of sodium hydroxide

Organic peroxides have caused many serious explosions and fires that were promoted by thermal instability, chemical pollutants, and even mechanical shock. Cumene hydroperoxide (CHP) has been employed in polymerization and for producing phenol and dicumyl peroxide (DCPO). Differential scanning calorimetry (DSC) has been used to assess the thermal hazards associated with CHP contacting sodium hydroxide (NaOH). Thermokinetic parameters, such as exothermic onset temperature (T ₀), peak temperature (T _max), and enthalpy (ΔH) were obtained. Experimental data were obtained using DSC and curve fitting using thermal safety software (TSS) was employed to obtain the kinetic parameters. Isothermal microcalorimetry (thermal activity monitor, TAM) was used to investigate the thermal hazards associated with storing of CHP and CHP mixed with NaOH under isothermal conditions. TAM showed that in the temperature range from 70 to 90°C an autocatalytic reaction occurs. This was apparent in the thermal curves. Depending on the operating conditions, NaOH may be one of the chemicals or catalysts incompatible with CHP. When CHP was mixed with NaOH, the T ₀ is lower and reactions become more complex than those associated with assessment of the decomposition of the pure peroxide. The data by curve fitting indicated that the activation energy (E _a) for the induced decomposition is smaller than that for decomposition of CHP in the absence of hydroxide.     

Thermodynamics of phenylated polyphenylene between 0 and 340 K

In an adiabatic vacuum calorimeter, the temperature dependence of the heat capacity C _p of phenylated polyphenylene and initial comonomer 1,4-bis(2,4,5-triphenylcyclopentadienone-3-yl)benzene was studied between 6 and 340 K with an uncertainty of about 0.2%. In a calorimeter with a static bomb and an isothermal shield their energies of combustion DUcomb were measured. From the experimental data, the thermodynamic functions C _p ⁰ (T), H ⁰(T)-H ⁰(0), S ⁰(T)-S⁰(0), G ⁰(T)-H ⁰(0) were calculated from 0 to 340 K, and standard enthalpies of combustion ΔH _comb ⁰ and thermodynamic parameters of formation-enthalpies ΔH _f ⁰, entropies ΔH _f ⁰, Gibbs functions ΔG _f ⁰ - of the substances studied were estimated at T=298.15 K at standard pressure. The results were used to calculate the thermodynamic characteristics (ΔH _f ⁰ ,ΔS _f ⁰, ΔG _f ⁰) of phenylated polyphenylene synthesis in the range from 0 to 340 K. This revised version was published online in July 2006 with corrections to the Cover Date.     

Fire and explosion properties examinations of toluene–methanol mixtures approached to the minimum oxygen concentration

The minimum oxygen concentration (MOC) is an important safety parameter of safety for fire/explosion prevention of practical processes with fuel-air-inert mixtures. In this study, the critical fire and explosion properties stand for the explosion sensitivity (lower explosion limit (LEL), upper explosion limit (UEL)), explosion maximum indices (maximum explosion pressure (P _max), maximum rate of explosion pressure rise (dP dt ⁻¹)_max) and explosion damage degree (gas or vapor deflagration index (K _g)/St Class). These imperative parameters of various toluene/methanol mixing solvents (100/0, 75/25, 50/50, 25/75 and 0/100 vol.%) were experimentally determined within a closed spherical vessel of 20 L (20-L-Apparatus) at 101 kPa and 150 °C. Particularly, we discussed the variations both on the above characteristics and implied flammability hazard degree within different initial oxygen circumstances; the specific effects on toluene/methanol mixing solvents were to be clarified accompanied with reducing loading oxygen concentrations, gradually approaching up to the MOC in this present work. Finally, a triangle flammability diagram with the five toluene/methanol components in our testing arrangements and conditions was established for graphically indicating the dangerous fire/explosion hazard region. It has been confirmed that this study would be very useful in relevant industrial processes for a proactive loss prevention program. The experimentally derived outcomes are recommended for the inherently safer design (ISD) for forestalling any accidents from fires and explosions.